CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND DATA, AND THEORY OF OPERATION
GENERAL INFORMATION
LIST OF ABBREVIATIONS/ACRONYMS
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
EQUIPMENT DATA
EQUIPMENT DATA - CONTINUED
EQUIPMENT DATA - CONTINUED
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS
OPERATOR CONTROLS - CONTINUED
OPERATOR CONTROLS - MODEL B
OPERATION UNDER USUAL CONDITIONS
OPERATION UNDER UNUSUAL CONDITIONS
STOWAGE AND DATA PLATES
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
CLEANING BALLISTIC GLASS
CHAPTER 4. UNIT MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
CLEANING INSTRUCTIONS - CONTINUED
PAINTING INSTRUCTIONS
USE OF THREAD ADHESIVE
DOOR HANDLE ASSEMBLY REPLACEMENT
DOOR HANDLE ASSEMBLY REPLACEMENT - CONTINUED
DOOR HANDLE ASSEMBLY REPLACEMENT - MODEL B
DOOR HANDLE ASSEMBLY REPLACEMENT - MODEL B - CONTINUED
DOOR LATCH AND LOCK PIN REPLACEMENT
DOOR LATCH AND LOCK PIN REPLACEMENT - CONTINUED
DOOR LATCH AND COMBAT LOCK REPLACEMENT - MODEL B
DOOR LATCH AND COMBAT LOCK REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR ASSEMBLY REPLACEMENT
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - MODEL B
DOOR ASSEMBLY REPLACEMENT - MODEL B - CONTINUED
DOOR ASSEMBLY REPLACEMENT - MODEL B - CONTINUED
DOOR LATCH ADJUSTMENT
DOOR LATCH ADJUSTMENT - CONTINUED
DOOR LATCH ADJUSTMENT - CONTINUED
DOOR LATCH ADJUSTMENT - MODEL B
DOOR LATCH ADJUSTMENT - MODEL B - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOUVERED GRILLE REPLACEMENT
LOUVERED GRILLE REPLACEMENT - CONTINUED
LOUVERED GRILLE REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
BLACKOUT DRIVE LIGHT REPLACEMENT
BLACKOUT DRIVE LIGHT REPLACEMENT - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ROOF ARMOR REPLACEMENT
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE BLAST DEFLECTOR REPLACEMENT
RIGHT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
RIGHT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
LEFT SIDE BLAST DEFLECTOR REPLACEMENT
LEFT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
LEFT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
REAR SIDE ARMOR REPLACEMENT
REAR SIDE ARMOR REPLACEMENT - CONTINUED
REAR SIDE ARMOR REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED
Table 1. MAC for the Crew Protection Kit
Table 1. MAC for the Crew Protection Kit - Continued.
Table 1. MAC for the Crew Protection Kit - Continued
Table 2. Tools and Test Equipment Requirements for the Crew Protection Kit
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items
Table 1. Expendable and Durable Items - Continued
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners
FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR PARTS LISTS (RPSTL) INTRODUCTION
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LISTS WORK PACKAGES
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
ABBREVIATIONS
REPAIR PARTS AND SPECIAL TOOLS LIST
Figure 1. Underbody Armor Protection Kit
Figure 1. Underbody Armor Protection Kit - Continued
Figure 2. Windshield Armor Protection Kit (Sheet 1 of 2)
Figure 2. Windshield Armor Protection Kit (Sheet 2 of 2)
Figure 2. Windshield Armor Protection Kit - Continued
Figure 2. Windshield Armor Protection Kit - Continued
Figure 3. Rear Cab Armor Protection Kit
Figure 3. Rear Cab Armor Protection Kit - Continued
Figure 4. Side Armor Kit, Left and Right Sides (Sheet 1 of 2)
Figure 4. Side Armor Kit, Left and Right Sides (Sheet 2 of 2)
Figure 4. Side Armor Kit, Left and Right Sides - Continued
Figure 4. Side Armor Kit, Left and Right Sides - Continued
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) (Sheet 1 of 3)
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) (Sheet 2 of 3)
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) (Sheet 3 of 3)
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) - Continued
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) - Continued
Figure 5A. Armor Door Assembly, Left and Right Side - Model B
Figure 5A. Armor Door Assembly, Left and Right Side - Model B - Continued
Figure 5B. Armor Door Assembly - Model B
Figure 5B. Armor Door Assembly - Model B - Continued
Figure 5B. Armor Door Assembly - Model B - Continued
Figure 6. Roof Armor Protection Kit
Figure 6. Roof Armor Protection Kit - Continued
Figure 6. Roof Armor Protection Kit - Continued
Figure 7. Front Armor Protection Kit (Sheet 1 of 2)
Figure 7. Front Armor Protection Kit (Sheet 2 of 2)
Figure 7. Front Armor Protection Kit - Continued
Figure 7. Front Armor Protection Kit - Continued
GROUP 94 REPAIR KITS
GROUP 94 REPAIR KITS - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
CREW PROTECTION KIT INSTALLATION INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
LIST OF ACRONYMS AND ABBREVIATIONS
Figure 1. HEMTT Crew Protection Armor Kit component location.
VERIFICATION OF TECHNICAL DATA
Figure 1-1. Crate No. 1 layout.
Figure 1-2. Crate No. 2 layout.
WARNINGS, CAUTIONS, AND NOTES
DESCRIPTION AND OPERATION
GENERAL
REMOVE EXISTING HEMTT COMPONENTS
Figure 2. Existing HEMTT components that are removed and retained.
Figure 3. HEMTT Door removal.
Figure 4. Remove the Male Dovetail and the Striker from the Door Frame.
Figure 5. Removing the Skid Plate.
Figure 6. Remove the Side Grab Handles.
Figure 7. Remove the Cab Step.
Figure 8. Loosen the Tire Carrier.
Figure 9. Remove the Fuel-Air Separator Guard.
Figure 11. Remove the windshield wiper.
Figure 12. Remove the windshield half.
Figure 13. Remove the Rear Cab Window.
Figure 14. Remove the Passenger-Side Roof Panel (Machine-Gun Mount) Attachment Bolts
HEMTT CREW PROTECTION ARMOR KIT INSTALLATION
PERSONNEL SKILL LEVEL
PARTS LIST
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
CREW PROTECTION ARMOR KIT ASSEMBLY PROCEDURES
NOTE
Figure 15. Windshield Bracket, Side Mounting.
Figure 16. Windshield Bracket, Bottom Mounting.
Figure 17. Windshield Frame pre-assembly.
Figure 18. Position the Windshield Armor Frame into the cab windshield opening.
Figure 19. Urethane Sealant and Ribbon Sealer vehicle locations.
Figure 20. "L" Bracket Installation.
Figure 21. Armor Windshield installation.
Figure 22. Windshield Wiper and Cleaning Decal installation.
Figure 23. Installing the Door Hinge and Hinge Bracket on the Front Cab Armor Panel
Figure 24. The correct Door Hinge orientation.
Figure 25. Install the amber clearance light and amber reflector onto the Front Side Cab Armor Panel.
Figure 26. Install the Headlight Covers.
Figure 27. Front HEMTT Armor Kit locations.
Install the Front Armor Protection Kit, P/N 106705-3
Figure 28. Left-hand Headlight Bracket Installed.
Install the Armored Louvered Grille
Figure 29. Move the Harness Bracket to the inside for increased clearance for the Rear Cab Armor Panel Bracket
Figure 30. Install Mounting Armor Brackets to the driver's-side rear cab armor panel.
Figure 31. Slide the Mounting Armor Brackets over the rear cab window opening edges.
Figure 29a. Armored washer locations.
Figure 32. Install the Armored Door Assembly to the cab (driver's-side door shown).
Install the LH and RH Armored Door Assembly Side Armor Kit P/N 106703-9 (Driver's-side) and P/N 106703-10 (Passenger-side)
Figure 33. Locate the Strap Assembly attachment point and Install the Door Striker.
Figure 33a. Locate and install the Door Striker.
Figure 33b. Door Striker Support Hole locations.
Figure 34. Install the new Attachment Strap to the Armored Door Assembly.
Figure 35. Install the Rear Side Cab Armor Panel.
Figure 35a. The Rear Side Cab Armor Panel installed.
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 36)
Figure 36. Blast Deflector installation (1 of 2).
Figure 36. Blast Deflector installation (2 of 2).
Figure 36A. Remove the drag link from the pitman arm on the steering box.
Figure 37A. Drill the holes for the Front Blast Deflector in the bottom of the fender support
Figure 38. Install the driver's-side front blast deflector (P/N 106717-1).
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 36) - Continued
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 36) - Continued
Figure 39. Position the Center Blast Deflector onto the Mounting Bracket Studs.
Figure 41. Re-install the drag link.
Figure 42. Re-install the Tire Carrier.
Figure 43. Roof Armor - front driver's-side installation.
Figure 45. Install the hatch seal.
Figure 45a. Roof Armor Assembly hardware installation.
Figure 46. Lift the Roof Armor Panel into place on the HEMTT roof.
Figure 47. Position the Roof Armor Panel Rear Bracket.
Figure 48. Secure the forward end of the Roof Armor Panel using the attachment hardware
Figure 48A. Escape Hatch Handle and Draw Latch illustration.
Figure 48b. Installation of the Escape Hatch Brackets.
Re-Install the LH and RH Door-Mounted Outside Mirrors
Figure 48B. Blackout Light installation.
Figure 49. Reversed Upper Brush Guard Cover.
APPENDIX A. FASTENER TORQUE VALUES
Table A-1. Torque Limits for Wet Fasteners
GEN IIIB INSTALLATION INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
LIST OF ACRONYMS AND ABBREVIATIONS
Figure 1. HEMTT Crew Protection Armor Kit component location.
CRATING / UNCRATING
Figure 1-1. Crate No. 1 layout.
Figure 1-2. Crate No. 2 layout.
DESCRIPTION AND OPERATION
GENERAL
REMOVE EXISTING HEMTT COMPONENTS
Figure 2. Existing HEMTT components that are removed and retained.
Figure 3. HEMTT Door removal.
Figure 4. Remove the Male Dovetail and the Striker from the Door Frame.
Figure 5. Removing the Skid Plate.
Figure 6. Remove the Side Grab Handles.
Figure 7. Remove the Cab Step.
Figure 8. Loosen the Tire Carrier.
Figure 9. Remove the Fuel-Air Separator Guard.
Figure 11. Remove the windshield wiper.
Figure 12. Remove the windshield half.
Figure 13. Remove the Rear Cab Window.
Figure 14. Remove the Passenger-Side Roof Panel (Machine-Gun Mount) Attachment Bolts
HEMTT CREW PROTECTION ARMOR KIT INSTALLATION
PERSONNEL SKILL LEVEL
PARTS LIST
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
CREW PROTECTION ARMOR KIT ASSEMBLY PROCEDURES
CREW PROTECTION ARMOR KIT ASSEMBLY PROCEDURES - Continued
Figure 15. Windshield Bracket, Side Mounting.
Figure 16. Windshield Bracket, Bottom Mounting.
Figure 17. Windshield Frame pre-assembly.
Figure 18. Position the Windshield Armor Frame into the cab windshield opening.
Figure 19. Urethane Sealant and Ribbon Sealer vehicle locations.
Figure 20. "L" Bracket Installation.
Figure 21. Armor Windshield installation.
Figure 22. Windshield Wiper and Cleaning Decal installation.
Figure 23. Install the Headlight Covers.
Figure 24. Front HEMTT Armor Kit locations.
Install the Headlights
Figure 25. Left-hand Headlight Bracket Installed.
Install the Rear Cab Armor Panels Kit P/N 106702-3
Figure 26. Move the Harness Bracket to the inside for increased clearance for the Rear Cab Armor Panel Bracket
Figure 26a. Armored washer locations.
Figure 28. Slide the Mounting Armor Brackets over the rear cab window opening edges.
Figure 28a. Armored washer locations.
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 29)
Figure 29. Blast Deflector installation (1 of 2).
Figure 29. Blast Deflector installation (2 of 2).
Figure 29a. Remove the drag link from the pitman arm on the steering box.
Figure 30a. Drill the holes for the Front Blast Deflector in the bottom of the fender support.
Install the Blast Deflectors, Kit P/N 106706-3 - Continued
Install the Blast Deflectors, Kit P/N 106706-3 - Continued
Figure 31. Position the Center Blast Deflector onto the Mounting Bracket Studs.
Figure 32. Secure the Center Blast Deflector to the Mounting Bracket.
Figure 33. Re-install the drag link.
Figure 34. Re-install the Tire Carrier.
Figure 35. Temporary Side Armor Panel positioning (showing rivnut pilot hole locations).
Install the Side Armor, Kit P/N 115500-1 (Driver's Side).
Install the Side Armor, Kit P/N 115500-1 (Driver's Side). - Continued
Figure 36. Side Armor Panel Side Seal Gasket attachment.
Figure 37. Side Armor Panel Assembly Attachment.
Figure 38. Roof Armor - front driver's-side installation.
Figure 40. Install the hatch seal.
Figure 41. Lift the Roof Armor Panel into place on the HEMTT roof.
Figure 42. Position the Roof Armor Panel Rear Bracket.
Figure 43. Secure the forward end of the Roof Armor Panel using the attachment hardware
Figure 44. Escape Hatch Handle and Draw Latch illustration.
Figure 45. Installation of the Escape Hatch Brackets.
Re-Install the LH and RH Door-Mounted Outside Mirrors
Figure 46. Blackout Light installation.
Figure 47. Reversed Upper Brush Guard Cover.
APPENDIX A. FASTENER TORQUE VALUES
Tabke A-1. Torque Limits for Wet Fasteners
C4ISR INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
LIST OF ACRONYMS AND ABBREVIATIONS
INTRODUCTION
HEMTT C4ISR MOUNTING HARDWARE KIT INSTALLATION
Figure 2.1. Right Rear Cab Armor Panel 106724-4 (Passenger Side).
Figure 2.2. Left Rear Cab Armor Panel 106724-3 (Driver's side).
Figure 2.3. PLGR Antennae mount.
C4ISR MOUNTING HARDWARE KIT ASSEMBLY PROCEDURES
Figure 3.1. Mounting Brackets.
Figure 3.2. Roof Support Bracket hole locations.
APPENDIX A. FASTENER TORQUE VALUES
GENERAL INFORMATION
LIST OF ABBREVIATIONS/ACRONYMS
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
EQUIPMENT DATA
EQUIPMENT DATA - CONTINUED
EQUIPMENT DATA - CONTINUED
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS
OPERATOR CONTROLS - CONTINUED
OPERATOR CONTROLS - MODEL B
OPERATION UNDER USUAL CONDITIONS
OPERATION UNDER UNUSUAL CONDITIONS
STOWAGE AND DATA PLATES
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
CLEANING BALLISTIC GLASS
CHAPTER 4. UNIT MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
CLEANING INSTRUCTIONS - CONTINUED
PAINTING INSTRUCTIONS
USE OF THREAD ADHESIVE
DOOR HANDLE ASSEMBLY REPLACEMENT
DOOR HANDLE ASSEMBLY REPLACEMENT - CONTINUED
DOOR HANDLE ASSEMBLY REPLACEMENT - MODEL B
DOOR HANDLE ASSEMBLY REPLACEMENT - MODEL B - CONTINUED
DOOR LATCH AND LOCK PIN REPLACEMENT
DOOR LATCH AND LOCK PIN REPLACEMENT - CONTINUED
DOOR LATCH AND COMBAT LOCK REPLACEMENT - MODEL B
DOOR LATCH AND COMBAT LOCK REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR BALLISTIC GLASS REPLACEMENT - MODEL B - CONTINUED
DOOR ASSEMBLY REPLACEMENT
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - MODEL B
DOOR ASSEMBLY REPLACEMENT - MODEL B - CONTINUED
DOOR ASSEMBLY REPLACEMENT - MODEL B - CONTINUED
DOOR LATCH ADJUSTMENT
DOOR LATCH ADJUSTMENT - CONTINUED
DOOR LATCH ADJUSTMENT - CONTINUED
DOOR LATCH ADJUSTMENT - MODEL B
DOOR LATCH ADJUSTMENT - MODEL B - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOUVERED GRILLE REPLACEMENT
LOUVERED GRILLE REPLACEMENT - CONTINUED
LOUVERED GRILLE REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
BLACKOUT DRIVE LIGHT REPLACEMENT
BLACKOUT DRIVE LIGHT REPLACEMENT - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ROOF ARMOR REPLACEMENT
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
RIGHT SIDE BLAST DEFLECTOR REPLACEMENT
RIGHT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
RIGHT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
LEFT SIDE BLAST DEFLECTOR REPLACEMENT
LEFT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
LEFT SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
REAR SIDE ARMOR REPLACEMENT
REAR SIDE ARMOR REPLACEMENT - CONTINUED
REAR SIDE ARMOR REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
FRONT SIDE ARMOR ASSEMBLY REPLACEMENT - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
SIDE ARMOR REPLACEMENT - MODEL B - CONTINUED
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED
Table 1. MAC for the Crew Protection Kit
Table 1. MAC for the Crew Protection Kit - Continued.
Table 1. MAC for the Crew Protection Kit - Continued
Table 2. Tools and Test Equipment Requirements for the Crew Protection Kit
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items
Table 1. Expendable and Durable Items - Continued
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners
FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR PARTS LISTS (RPSTL) INTRODUCTION
EXPLANATION OF COLUMNS IN THE REPAIR PARTS LISTS WORK PACKAGES
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
ABBREVIATIONS
REPAIR PARTS AND SPECIAL TOOLS LIST
Figure 1. Underbody Armor Protection Kit
Figure 1. Underbody Armor Protection Kit - Continued
Figure 2. Windshield Armor Protection Kit (Sheet 1 of 2)
Figure 2. Windshield Armor Protection Kit (Sheet 2 of 2)
Figure 2. Windshield Armor Protection Kit - Continued
Figure 2. Windshield Armor Protection Kit - Continued
Figure 3. Rear Cab Armor Protection Kit
Figure 3. Rear Cab Armor Protection Kit - Continued
Figure 4. Side Armor Kit, Left and Right Sides (Sheet 1 of 2)
Figure 4. Side Armor Kit, Left and Right Sides (Sheet 2 of 2)
Figure 4. Side Armor Kit, Left and Right Sides - Continued
Figure 4. Side Armor Kit, Left and Right Sides - Continued
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) (Sheet 1 of 3)
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) (Sheet 2 of 3)
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) (Sheet 3 of 3)
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) - Continued
Figure 5. Armored Door Assembly, Left and Right Sides (Model A) - Continued
Figure 5A. Armor Door Assembly, Left and Right Side - Model B
Figure 5A. Armor Door Assembly, Left and Right Side - Model B - Continued
Figure 5B. Armor Door Assembly - Model B
Figure 5B. Armor Door Assembly - Model B - Continued
Figure 5B. Armor Door Assembly - Model B - Continued
Figure 6. Roof Armor Protection Kit
Figure 6. Roof Armor Protection Kit - Continued
Figure 6. Roof Armor Protection Kit - Continued
Figure 7. Front Armor Protection Kit (Sheet 1 of 2)
Figure 7. Front Armor Protection Kit (Sheet 2 of 2)
Figure 7. Front Armor Protection Kit - Continued
Figure 7. Front Armor Protection Kit - Continued
GROUP 94 REPAIR KITS
GROUP 94 REPAIR KITS - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
CREW PROTECTION KIT INSTALLATION INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
LIST OF ACRONYMS AND ABBREVIATIONS
Figure 1. HEMTT Crew Protection Armor Kit component location.
VERIFICATION OF TECHNICAL DATA
Figure 1-1. Crate No. 1 layout.
Figure 1-2. Crate No. 2 layout.
WARNINGS, CAUTIONS, AND NOTES
DESCRIPTION AND OPERATION
GENERAL
REMOVE EXISTING HEMTT COMPONENTS
Figure 2. Existing HEMTT components that are removed and retained.
Figure 3. HEMTT Door removal.
Figure 4. Remove the Male Dovetail and the Striker from the Door Frame.
Figure 5. Removing the Skid Plate.
Figure 6. Remove the Side Grab Handles.
Figure 7. Remove the Cab Step.
Figure 8. Loosen the Tire Carrier.
Figure 9. Remove the Fuel-Air Separator Guard.
Figure 11. Remove the windshield wiper.
Figure 12. Remove the windshield half.
Figure 13. Remove the Rear Cab Window.
Figure 14. Remove the Passenger-Side Roof Panel (Machine-Gun Mount) Attachment Bolts
HEMTT CREW PROTECTION ARMOR KIT INSTALLATION
PERSONNEL SKILL LEVEL
PARTS LIST
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
CREW PROTECTION ARMOR KIT ASSEMBLY PROCEDURES
NOTE
Figure 15. Windshield Bracket, Side Mounting.
Figure 16. Windshield Bracket, Bottom Mounting.
Figure 17. Windshield Frame pre-assembly.
Figure 18. Position the Windshield Armor Frame into the cab windshield opening.
Figure 19. Urethane Sealant and Ribbon Sealer vehicle locations.
Figure 20. "L" Bracket Installation.
Figure 21. Armor Windshield installation.
Figure 22. Windshield Wiper and Cleaning Decal installation.
Figure 23. Installing the Door Hinge and Hinge Bracket on the Front Cab Armor Panel
Figure 24. The correct Door Hinge orientation.
Figure 25. Install the amber clearance light and amber reflector onto the Front Side Cab Armor Panel.
Figure 26. Install the Headlight Covers.
Figure 27. Front HEMTT Armor Kit locations.
Install the Front Armor Protection Kit, P/N 106705-3
Figure 28. Left-hand Headlight Bracket Installed.
Install the Armored Louvered Grille
Figure 29. Move the Harness Bracket to the inside for increased clearance for the Rear Cab Armor Panel Bracket
Figure 30. Install Mounting Armor Brackets to the driver's-side rear cab armor panel.
Figure 31. Slide the Mounting Armor Brackets over the rear cab window opening edges.
Figure 29a. Armored washer locations.
Figure 32. Install the Armored Door Assembly to the cab (driver's-side door shown).
Install the LH and RH Armored Door Assembly Side Armor Kit P/N 106703-9 (Driver's-side) and P/N 106703-10 (Passenger-side)
Figure 33. Locate the Strap Assembly attachment point and Install the Door Striker.
Figure 33a. Locate and install the Door Striker.
Figure 33b. Door Striker Support Hole locations.
Figure 34. Install the new Attachment Strap to the Armored Door Assembly.
Figure 35. Install the Rear Side Cab Armor Panel.
Figure 35a. The Rear Side Cab Armor Panel installed.
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 36)
Figure 36. Blast Deflector installation (1 of 2).
Figure 36. Blast Deflector installation (2 of 2).
Figure 36A. Remove the drag link from the pitman arm on the steering box.
Figure 37A. Drill the holes for the Front Blast Deflector in the bottom of the fender support
Figure 38. Install the driver's-side front blast deflector (P/N 106717-1).
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 36) - Continued
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 36) - Continued
Figure 39. Position the Center Blast Deflector onto the Mounting Bracket Studs.
Figure 41. Re-install the drag link.
Figure 42. Re-install the Tire Carrier.
Figure 43. Roof Armor - front driver's-side installation.
Figure 45. Install the hatch seal.
Figure 45a. Roof Armor Assembly hardware installation.
Figure 46. Lift the Roof Armor Panel into place on the HEMTT roof.
Figure 47. Position the Roof Armor Panel Rear Bracket.
Figure 48. Secure the forward end of the Roof Armor Panel using the attachment hardware
Figure 48A. Escape Hatch Handle and Draw Latch illustration.
Figure 48b. Installation of the Escape Hatch Brackets.
Re-Install the LH and RH Door-Mounted Outside Mirrors
Figure 48B. Blackout Light installation.
Figure 49. Reversed Upper Brush Guard Cover.
APPENDIX A. FASTENER TORQUE VALUES
Table A-1. Torque Limits for Wet Fasteners
GEN IIIB INSTALLATION INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
LIST OF ACRONYMS AND ABBREVIATIONS
Figure 1. HEMTT Crew Protection Armor Kit component location.
CRATING / UNCRATING
Figure 1-1. Crate No. 1 layout.
Figure 1-2. Crate No. 2 layout.
DESCRIPTION AND OPERATION
GENERAL
REMOVE EXISTING HEMTT COMPONENTS
Figure 2. Existing HEMTT components that are removed and retained.
Figure 3. HEMTT Door removal.
Figure 4. Remove the Male Dovetail and the Striker from the Door Frame.
Figure 5. Removing the Skid Plate.
Figure 6. Remove the Side Grab Handles.
Figure 7. Remove the Cab Step.
Figure 8. Loosen the Tire Carrier.
Figure 9. Remove the Fuel-Air Separator Guard.
Figure 11. Remove the windshield wiper.
Figure 12. Remove the windshield half.
Figure 13. Remove the Rear Cab Window.
Figure 14. Remove the Passenger-Side Roof Panel (Machine-Gun Mount) Attachment Bolts
HEMTT CREW PROTECTION ARMOR KIT INSTALLATION
PERSONNEL SKILL LEVEL
PARTS LIST
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
PARTS LIST - Continued
CREW PROTECTION ARMOR KIT ASSEMBLY PROCEDURES
CREW PROTECTION ARMOR KIT ASSEMBLY PROCEDURES - Continued
Figure 15. Windshield Bracket, Side Mounting.
Figure 16. Windshield Bracket, Bottom Mounting.
Figure 17. Windshield Frame pre-assembly.
Figure 18. Position the Windshield Armor Frame into the cab windshield opening.
Figure 19. Urethane Sealant and Ribbon Sealer vehicle locations.
Figure 20. "L" Bracket Installation.
Figure 21. Armor Windshield installation.
Figure 22. Windshield Wiper and Cleaning Decal installation.
Figure 23. Install the Headlight Covers.
Figure 24. Front HEMTT Armor Kit locations.
Install the Headlights
Figure 25. Left-hand Headlight Bracket Installed.
Install the Rear Cab Armor Panels Kit P/N 106702-3
Figure 26. Move the Harness Bracket to the inside for increased clearance for the Rear Cab Armor Panel Bracket
Figure 26a. Armored washer locations.
Figure 28. Slide the Mounting Armor Brackets over the rear cab window opening edges.
Figure 28a. Armored washer locations.
Install the Blast Deflectors, Kit P/N 106706-3 (see Figure 29)
Figure 29. Blast Deflector installation (1 of 2).
Figure 29. Blast Deflector installation (2 of 2).
Figure 29a. Remove the drag link from the pitman arm on the steering box.
Figure 30a. Drill the holes for the Front Blast Deflector in the bottom of the fender support.
Install the Blast Deflectors, Kit P/N 106706-3 - Continued
Install the Blast Deflectors, Kit P/N 106706-3 - Continued
Figure 31. Position the Center Blast Deflector onto the Mounting Bracket Studs.
Figure 32. Secure the Center Blast Deflector to the Mounting Bracket.
Figure 33. Re-install the drag link.
Figure 34. Re-install the Tire Carrier.
Figure 35. Temporary Side Armor Panel positioning (showing rivnut pilot hole locations).
Install the Side Armor, Kit P/N 115500-1 (Driver's Side).
Install the Side Armor, Kit P/N 115500-1 (Driver's Side). - Continued
Figure 36. Side Armor Panel Side Seal Gasket attachment.
Figure 37. Side Armor Panel Assembly Attachment.
Figure 38. Roof Armor - front driver's-side installation.
Figure 40. Install the hatch seal.
Figure 41. Lift the Roof Armor Panel into place on the HEMTT roof.
Figure 42. Position the Roof Armor Panel Rear Bracket.
Figure 43. Secure the forward end of the Roof Armor Panel using the attachment hardware
Figure 44. Escape Hatch Handle and Draw Latch illustration.
Figure 45. Installation of the Escape Hatch Brackets.
Re-Install the LH and RH Door-Mounted Outside Mirrors
Figure 46. Blackout Light installation.
Figure 47. Reversed Upper Brush Guard Cover.
APPENDIX A. FASTENER TORQUE VALUES
Tabke A-1. Torque Limits for Wet Fasteners
C4ISR INSTRUCTIONS
EQUIPMENT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
LIST OF ACRONYMS AND ABBREVIATIONS
INTRODUCTION
HEMTT C4ISR MOUNTING HARDWARE KIT INSTALLATION
Figure 2.1. Right Rear Cab Armor Panel 106724-4 (Passenger Side).
Figure 2.2. Left Rear Cab Armor Panel 106724-3 (Driver's side).
Figure 2.3. PLGR Antennae mount.
C4ISR MOUNTING HARDWARE KIT ASSEMBLY PROCEDURES
Figure 3.1. Mounting Brackets.
Figure 3.2. Roof Support Bracket hole locations.
APPENDIX A. FASTENER TORQUE VALUES